Casting machine



` Sept. lo, 1.946. vc;, WES'SEL A 2,407,334

l 'CASTING MACHINE Filed April 16, 1942 s sheets-sheet 1 www.

3 Sheets-Sheet 2 c; wEssEL CASTING MACHINE Filed April 1e, 1942 l 1w faz f :im Q7 zj,

y w QW@ Sept. 10, 1946.

Sept. l0, 1946.

c. wEssEL CASTING lMACHINE vFiled April 16, 1942 I5- Sheets-Sheet 3 Patented Sept. l0, 1946 CASTING MACHINE Carl Wessel, Chicago, Ill., assigner to Carl Wessel and Lew W. Cleminson, both of Chicago, Ill., as

trustees Application April is, 1942, serial No. 439,190

17 Claims.

The present invention relates to casting maehines and is particularly concerned with apparatus for producing better castings more efciently and more economically than can be done by the methods and apparatus of the prior art.

The present application is a continuation in part of my prior application, Serial No. 251,092, led January 16, 1939, on Metal castings, methods and machines for casting the same, which issued as U. S. Patent No. 2,287,848, on June 30, 1942, entitled Method of casting. i

One of the objects of the present invention is the provision of an improved apparatus for casting metal, utilizing refractory molds, and lilling the mold by gravity of the liquid metal in suchv manner that the complete lling of the mold is effected and the shrinkage is avoided by the continuous application c-f liquid metal under pressure, due to gravity head, while the casting is cooling from its most remote end toward the filling gate.

Another object of the invention is the provision cf an improved apparatus' for casting by means of which extremely thin sections may be made and by means of which the freezing of a part of the metal during the pouring process, commonly referred to as blow-holes, may be eliminated. y

Another object of the invention is the provision of an improved apparatus for casting which produces anabsolutely solid casting and produces'a high degree of uniformity of crystal structure of the casting, and which is also economical in its operation.

Another object of the invention is the provision of an improved apparatus for casting which avoids the contamination of the metal by lling the mold without the liquid metal coming in contact with any air except that small amount which is present in the mold.

Another object of the invention is the provision of an improved apparatus forcasting kwhich is adapted to avoid shrinkage by means of the continuous application of metal in liquid form under pressure Vhead due to gravity for a predetermined time, so that the congelation of the metalfmay be accomplished while pressure is applied.

Another object of the invention is the provision of improved apparatus for producing castings, by means of which shrinkage, flaws, and the formation of pipes and shrinking strains are eliminated, and castings of uniform crystal structure may be produced at a minimum cost.

Another object of the invention is the provi- Lsion of an improved apparatus which permits the melting and casting of the metal under reduced air, or controlled air conditions'as required by the metal used.

Other objects and advantages of the invention will be apparent from the following description and the accompanying drawings, in which similar characters of reference indicate similar parts throughout the several views.

Referring to the drawings which accompany this specication,

Fig. 1 is a diagrammatic top plan View of a plurality of melting furnaces arranged Yfor discharge into a centrally located ladle;

Fig. 2 is a similar View of a modied furnace and ladle arrangement;

Fig. 3 is a top plan sectional View, taken on the plane of the line 3-3 of Fig. 4, showing the structure of the ladle of Figs. 1 and 2;

Fig. 4 is a vertical sectional View, taken von the plane of the line 4 4 of Fig. 3, looking in the direction of the arrows, showing the structure of kthe ladle and the closely associated part of the mold;

Fig. 5 is a fragmentary sectional View of a modied form of connection between the ladle and the mold, which may be utilized in Fig. 4;

Fig. 6 is a fragmentary elevational front view ofthe front part of the ladle and conveying mechanism for supporting the molds in moldlling position; i Y n Fig. 7 is a side elevational view in partial section, showing a modied form of a tilting ladle mold, and support for they same, which is adapted to be used in small plants for accomplishing Very desirable results accordingV to the present invention, with the mold in the position which it assumes before the mold-filling operation;

Referring to Figs. 1 and 2, these are diagrammatic arrangementsY of a plurality of furnaces, shown in connection with a ladle of the type illustrated in Figs. 3 and 4.y

According to my method of operation ina foundry ofsuitable size, the ladle 20 is provided pounds per hour; while, if three furnaces were employed., a batch would be discharged every twenty minutes. Under these conditions the capacity of the ladle might be approximately 12pt) pounds or two cubic feet, and the inner measurements' of the ladle might be, for example, ten inches inner diameter by thirty inches high.

The temperature of the metal discharged yfrom the furnaces might be approximately 2200 den grecs-F., and 'the temperature of the metal in the ladle might `be slightly lower, but need Inot vary more than about 200 degrees F., as the heat of the -metal in the ladle would be continuously replenished by the periodic discharge into the ladle of hotter metal from the furnaces.

Each furnace is preferably provided with a rotating discharge spout 21, and the ladle or reservoir 2G is preferably provided with a suitable cover, which is removable, so that the metal is fenclos'ed from the time it is melted in the furnace and during its V'discharge into the ladle and during its discharge from the ladle into the mold, as will be further described.

A cleaning of the metal is effected in the furnace before the pouring operation by scraping out the dross a-ndslag, with the furnace almost in level position, the scraping being effected through a `discharge opening, y

The melting may ythen 'be accomplished under 'l reduced air land controlled conditions.

In the example of a furnace and ladle proportion cited, the head of pressure might vary from ful-l head in the ladle to half head during most Y of the days casting. At the end of the days run, i"

the reduced head, from one-half to zero in the "ladle, would be utilized for the casting of 'relatively small molds, which would not require as 'much gravity head as the larger` castings, The total capacity per day for an eight hour day of casting would be approximately 7,000 pounds.

It is to be understood that the `sizes which have been given for the parts lof the ladle and the capacities of the ladle given above are merely exemplary, and 4the 4present apparatus maybe constructed in large or small sizes, depending upon the results desired.

Referring to Fig. 1, each of the melting furnaces VEll is, of course, providedV with a suitable heating device, such as a gas or oil burner, and may be provided with a motor for rotating, and

veach furnace of course comprises an internal hre-brick insulation supported by a metal jacket as shown.

In Fig. 1 the discharge spouts, which are also 'i provided with a metal jacket and a `rebrick lining'or refractory lining, may all be of the same length, thereby assuring equal temperature for the discharged metal from each of the furnaces. I

In Fig. 2 the .furnaces 3ft-'33 each discharge into the discharge conduits 34-31, and the two vco-nduits 3d, 35 and 36, 37 are joined to conduits 38, 39 respectively. In this case the lengths of the conduits for all of the furnaces are not equal,

Vof I beams 4 but by means of the use of Va suitable refractory ining for the metal jacketed conduits 34-39 the excessive loss of heat can be practically eliminated and practically the same discharge temperature secured for the batch from each furnace.

In the event the end furnaces 3S and 33 give evidence of slightly greater cooling of the batch as it discharges `down the elongated conduits 34, 38 and 3l, 39, the end furnaces can be operated Lat slightly higher temperatures, to effect equalisation of the temperature of the batches discharged into ladle 2?, which is similaiin construction to the ladle or reservoir 2B, previously described.

Vling molds from this reservoir.

In Figs. 3 and 4 the ladle, which is indicated in its entirety by the numeral 253, may have its interior insulation 2l formed in a plurality of layers, the layers comprising, respectively, the inner refractory do, the iirebrick d l, and the rock wool'or asbestos'ber insulation 42.

The ladle 2@ is preferably supported upon a suitable concrete foundation 43 and may have its external metal jacket i4 built up of a -multiplicity of metal sections '4E-5l. These metal sections are in the for-m of endless metal bands of cylindrical shape, each successive section being supported upon the one below it so that the ladle can be built to any desired height.

rIhe metal jacket sections 45--51 are givenadvditional support and heldin alignment with each other by "a vplurality of vertically extending I beams 52-55 (Fig. 3)., which are preferably equally spaced about the periphery of the metal jacket 4d, extend axially thereof, and are located in contact with the external cylindrical surface of the jacket sections l5-5 l.

At each joint 'between the jacket sections there is a metal band i, and yeach metal band may be Yof similar construction to those shown in Fig. 3. rihe metal bands '5S-@l are bent to substantially partially cylindrical form, and are long enough to encompass that portion of the periphery Iwhich is located between the flanges of a pair 52;-555 Any number `of I beams may be employed, `but Sin 'furnace -o'f the mentioned above I consider four I beams sufcient, 'and `the metal bands Si, for example, contact the external surfaces of the sections 5@ and 5l of the jacket @d throughout the major portion of their length, and are bent outward vatei or provided wfith'an offset 52 at each end so as to engage outside the inner flange E3 of the I beams.

The bands 5t to 6i are also provided with an attachment flange Ed extending radially at each end and adapted to engage 'the web E5 of the I beam 513 or and the attachment vflanges 65 are provided with apertures for receiving the screw bolts 5%, which pass through 'the attachment flanges -Gil `and through the web Ee, and secure two of the attachment flanges of the bands Eil- Sl to each web.

The bands 55E-5i are slightly shorter in length than the spaces between the webs of the respec- Ytive I beams 54, 55 so that there is a tolerance to be taken up -by means of the bolts 66, which draw'the bands tightly about the Ymetal sections 45-5! the jacket l and assure the securement of these bands against vertical movement due to the frictional engagement between the bands and the metal sections.

The ladle also comprises an inner metal'shell of similar construction to the metal shell 44, or the inner metal shell may comprise the simple annular bandsof metal, such as steel, mounted one upon the other in such a way as to overlap the joints between the rebricks. The Space between the two shells 44 and 10 may be lledwith rock Wool, high temperature asbestos fiber, such as Amosite, glass wool, or quartz wool, for the purpose of conserving the heat in the ladle.

Inside the shell 10, the ladle is provided with the layer 4I of rebrick, molded to ft together to form a wall which is annular in plan, and the firebrick preferably have their joints overlapping the joints between the sections of the inner shell 10. For example, if the rebrick are also one foot high, then this also facilitates the building of various sizes of ladles or reservoirs which diier in height by a foot.

The innermost layer of insulation comprises the refractory lining 40, which consists of a refractory composition that is smooth but not glazed, and which may be treated with flux or charcoal to prevent the metal from sticking to it.

The composition may include metal dioxides, clay, and feldspar, and such refractory linings may be made absolutely smooth so that the metal in the reservoir can be kept clean.

A de-oxidizer compound can be kept on top of the charge in the reservoir or ladle 20 for the purpose of preventing any air contamination.

An alternative mode of preventing air contamination is to provide a gas burner whose name plays on the full free surface of the molten metal in sufficient amount t0 exclude oxygen, or to use some other `non-inflammable inert gas used in the samel Way when the raw material is explosive or inflammable as magnesium.

The refractory lining 40 is also in the form of` peripheral sections, which, for example, may be a foot high, and all of which t together smoothly to form the cylindrical reservoir chamber 1I for receiving the molten metal.k This chamber is substantially cylindrical in shape at its uppermost portion, such as, for example, the sections 12, 13,

,tapers still farther along smoothly curved lines toward the reduced conduit 80 in the refractory block 8| at the side wall of the ladle.

The metal jacketsection 46is provided with an enlarged aperture 32,` for receiving the refractory block 83, which may be cylindrical in form, andwhich is provided with the discharge aperture 23, forming a continuation of the conduit 80.

'The refractory block 83 may be housed in a cast metal fitting sa Fig. 4), which is provided with an inner curved surface 85, and peripherally extending flanges 85, 81 fit against a metal band 923 surroundingthe wall of the section 45, to which the flanges 36, 81 are bolted by means of the 'screw bolts 83, which have their threaded ends projecting outward from the shell 46.

n The` fitting 84 may be built up in the form of a plurality of metal sections 90, 9|, 92, bolted or otherwise secured together, but the external por- `6 tion 92 thereof isprovided with laterally projecting flanges 93 and vertically projecting flanges 94, forming internally directed guide grooves 95, 96 rfor receiving a complementary partv carried by a mold.

Y The guide grooves 95, 96 extend parallel to each other and in straightllines so that the flanges 91, 98 carriedby the mold may be slidably mounted in the grooves 95, 98. Each of the molds Idd-I 05 may comprise a metal lining and an external metal jacket |06 formed of two similar halves |01 |08 fitting together.

, vThe jacket halves |01, |08 are lined with an inner layer |09, I I0 of smooth high-temperatureresistant and heat-insulating refractory, previously mentioned, which is used to line the inner- Vmost chamber 1I of the ladle, and the refractory sections |09, IIO of the mold have the casting cavity III formed in them, and are separable at the samejoint II2 as the metal halves |01, |08 of the jacket It. For the purpose of illustration, the mold IGI is illustrated with a jacket comprising two separable sections which are clamped or bolted tog-ether in any suitable way, preferably by means of pivoted bolts and wing nuts so that the molds may be removed quickly at the propertime. However, the molds may be made of any number of sections suitable to the nature of the shape of the casting so as to facilitate the removal of the mold from the casting as soon as it has congealed, without breaking any part of the casting.

The proper number of sections for a jacket or refractory lining of a mold will be evident to'anyone skilled in the art of molding.

The present molds are adapted to be used over and overagain, and are practically indestructible.

They are also preheated before use, and are maintained in a heated condition by re-use, the number of molds being adapted to the continuous operation of the machine by the use of a mold practically as soon as it has been removed from one congealed casting which is still at a hlighly heated condition.

mation which is adapted to be secured to the guide fitting I I1, having the flanges 91, 98 previously mentioned. This guide fitting has a pair of outwardly extending flanges II8'and a pair of downwardly and upwardly extending flanges I|9. and is provided with set screws |20 for secwrement to the mold.

It will be noted that in Fig. 4 the mold IDI, which is for a relatively at casting, extends diagonally upwardly.v This is for the purpose of permitting the filling of the mold by the flowing upward of the melted metal in the mold, without any. splashing or formation of drops.

It is contemplated that no special gates will be required for the discharge of the air in the mold, as the air may leak out between the two halves of the refractory lining and metal jacket of the mold, which are tted closely enough to mold the casting with practically no fin, but still l permit the escape of air. 1

The air compressed in the mold and forced out through the cracks causes the metal to well up more slowly, thereby preventing hammer, shock, and turbulence.

It will be noted that the reservoir vor ladle 2i) is formed with a downwardly vand laterally extending discharge conduit, which tapers gradually to its smallest section at the mouth |2| of the casting cavity. The molds may thus be slidably supported by means of the guide .fixture 84, which is located not only in front of the furnace, but extends longitudinally from the furnace in a straight line, so as to support a multiplicity of molds, as shown in Fig. 6. In some embodiments of the invention the ladle .may be provided with a plurality of discharge openings for yan equal number of molds.

In some plants the molds may be shoved past the discharge aperture 23 of the ladle by hand. As soon as the aperture ||6 of the mold has passed the discharge aperture 23, the further dis- -charge of melted metal is arrested by the fact that the flat surfaces on the face |22 of the refractory of the mold cover up the discharge aperture 23.

If desired, a suitable steel die may be provided at this face |22 for shearing off any metal which may have congealed.

In the practice of my method, the metal, which may be congealed slightly, will still be capable of being sheared oi at this time.

`When the molds are shoved into place by hand, there will be suitable stops such as pins, placed in apertures in the fitting 84 for stopping the mold, with the apertures 23 and i5 in registry, and the rpulling of the stop pin or movement ci the stop member out of its operative position will permit the progress of the mold from the casting position to a position further on in` the guides of the guide iixture 84.

In other embodiments of the invention a suitable driving mechanism may be provided, such as, for example, the frame members |30 (Fig. 6) which support a driving rack |3| that is slidably mounted by means of the pins |32 in slots |33 below the molds.

This rack may be spring-urged toward the right by means of a tension spring |34 engaging a pin on the rack, and having its opposite end secured to a frame member The rack is provided Awith a plurality of pawls 'IE5-|49. Each pawl ld-Mil is pivotally mounted upon a pin 14| and engages a stop member |42, toward which it is pulled by means of a spring |43.

The rack bar |35 also has a driving pin ille suitably located to be engaged by the shoulder |49 carried by a rotating drive wheel |59 mounted 'on shaft l5 i.

rIhe operation cf this step-'by-step mechanism is as follows: Shaft l! may rotate at a constant speed, which is determined by the length of time required for the making of one casting. This time will be suiiicient, as Vhereinafter more fully described, to permit not only the filling of the mold with melted metal, but the continued application of melted metal under gravity head to the mold while the Acasting con'geals from its outermost point inward toward the supply of metal in the reservoir.

lDuring this congelation the shrinkage of the casting is taken up by the sup-ply of additional metal from the molten end of the casting, and the last part of the casting to freeze should be that adjacent the mouth 0f the mold. Thus the actuating shoulder |49 performs arotation in a predetermined time, which'is'deter- .mined by the characteristics of the 'casting cir S mold and by the time `required to carry out my process.

When the shoulder |49 engages the pin |155, it causes the rack |3| to move to the left by an amount equal to the length of a slot |33, which is sufficient to move one mold lill from the po sition which it occupies in Fig. 5, in registry with the discharge aperture 23, and to bring the vnext mold |92 into that same position. Thereafter the shoulder IEB slips olf and passes the pin |45, due to the rotation or the wheel IES, and the spring |3l returns the rack ISI, during which movement all of 'the pawls i 3'5-1130 are adapted to slide past the molds which are immediately to the right of each pawl.

The pawls are then in position to engage and actuate these molds when the rack has reached the position of Fig. 6 again. Thus the mechanism is adapted to eiiect the movement of the molds in a Ystep-by-step manner and -to permit the molds to remain in casting position for a predetermined length of time.

Referring again to Fig. 4c, the ladle is Ypreferably provided with a fixed cover member |663, which may comprise a metal jacket lf'l having an external cylindrical portion E62 and a fiat end portion |63.

The jacket i6! may be bolted in place by means of the bolts ltd and anges |65, l. The `jacket may have a centrally located aperture |61 with a downwardly extending frusto-conical flange Hi8. The jacket is lined with a flat block of refractory |769 in the form of a ydisc having a centrally located frusto-conical bore |16 fitting against the iiange |63.

rihis aperture Il@ serves as a iilling opening for the reservoir or ladle 1|, and it in turn may be closed by a movable cover member l1 i, which has a metal jacket |12 and a refractory lining |13 retained by means of a frusto-conical flange lill, The movable cover l1! ts in the bore |61 and produces an effective closure, due to the en" gagement of the metal flanges |63 and |14.

The movable cover Ell may be provided with a centrally located air aperture |15, communicating with a counterbore |15 for receiving a conical valve member |11. The valve member ||1 has a stem |13 guided in an aperture in the jacket |12 and urged to closed position by a spring |19. The stem il@ has a transverse pin I8@ engaging in a slot in the end of 'a lever I3 rIhe lever ibi is pivoted on the bracket |32 and provided at its opposite end with a pull rod |83 slidably mounted in a guide xture |34 and provided with a ball counter-'balance |85. By means of a pull on the rod |63 the operator may regulate the admission of air to the chamber l1| of ladle 253, and thus control, at least in some measure, the discharge of metal from its lower end.

Thus the pull rod |33 would be pulled whenever the mold was in front of the discharge aperture of the ladle, and the actuation of the rod may be gradual, in order to permit the filling of the mold without any splashing, or to reduce the impact which results when the molten metal flowing into the mold reaches the end of the mold.

Referring to Fig. 5, this is a lmodiiication in which the conduit i5 is provided with a butterfly valve 210 for controlling the now of the metal into the mold.

This valve may be so construct-ed that its actuating shaft may be withdrawn, and that portion of the conduit H5 surrounding it maybe separated when the mold is separated, so that the 9 'metal in the conduit H5 may be removed from the conduit with the valve 210, and a new valve substituted when the mold is again used.

My method of castingis briefly described a follows: When a ladle of the type described is used, the Yladle is constantly supplied with new batchesof molten metal, from which all dross or scum have been removed in the furnace, and this metal is supplied to the ladle without exposure to the air, so far as possible.

A de-oxidizer compound" may be kept on top of the charge, to prevent air contamination. The molten metal is kept in the ladle, which is lined with smooth refractory, suitably treated with flux or charcoal, to prevent the metal from sticking to it, and suitably insulated, so that the metal may be maintained at a high temperature, with a minimum fluctuation `of temperature between batches.

When ordinary castings are to be made, the mold is made of a similar smooth refractory capable of retaining the heat, and providing heat insulation for the casting, and the mold is preheated either by a preheating operation or by being used over and over again, immediately after a previous casting Operation.

The mold and the ladle have their entry and l discharge openings and conduit for the metal smoothly tapered along stream lines so that there will be no splashing and the least amount of agitation of the metal.

The mold may be lined with metal inside the refractory to reduce breakage of molds and irnprove castings, and when casting with certain metals I use metalmolds where it is economical.

The mold is tilted upward from its filling opening so that metalw running into the mold cannot drop down to the end of the mold and splash.

After the mold opening is placed in registry with the discharge opening of the ladle, the molten metal is permitted to well up into the mold, its level constantly rising, until it completely fills the mold.

' Duringthis time the metal is still molten and maintained heated because of the insulating character of the refractory mold or the preheating of the mold. Y Y

The mold may, in the case of relatively large castings, be provided with apertures for the issuance'ofthe air, but in most cases the air'will leak out between the halves of the mold, and th'e moldsin such case will not need risers.

The method may be practised with all types of metals. Y mold and in the ladle are proportionate to the bulk of the metal in the casting or the bulk of the metal in the ladle,A respectively.

After the mold has been filled, it is then maintained in the same position, with the metal of the ladle pressing into the mold, due to the head of the metal in the ladle, until the metal has solidified in the mold.

During this operation the pouring end of the mold is the hottest, and the end farthest from the ladle isy the coolest. There'is a heat gradient extending Yfrom the ladle outward to the extreme end of the mold. As the metal solidies, it begins to solidify at the eitreme end of the mold,away from the ladle, and gradually solidies downward toward the lling opening of the mold. During this operation'any shrinkageis taken up by the supply of additional melted metal, due to the head of the'metal in the-ladle.

There will be no flaws or pipes, nor will the casting be subjected to strains due to unequal con- 'Ihe thickness of the refractory in the 10 traction. The entire mold will be filled, and the casting will correspond more closely to the shape of the mold than with the methods of the prior art.

After the casting has solidified in the mold down to the lling opening of the mold, the further ilow of metal into the mold is cut off by sliding the mold Sidewise so that the stream of metal is sheared off. If it has solidified. down to the point of shearing, it can still be sheared off, due to its relative softness at such Aa high temperature, and the discharge aperture of the ladle is closed bya flat surface on the end of the mold. f

The next mold continues to close this discharge opening by a, similar flat surface until its filling opening comes in registry with ythe discharge opening of the ladle, after which the lling'of the mold is again resumed. Y

The mold, which has been filled and removed from its ladle, has its parts separated, and the casting is removed at a proper time, which is determined by the character of the casting.l This enables the use of the mold over again While it is still in a heated condition, and the casting may contract as it cools, without producing any strains on the mold or breaking thel mold. The casting may contract more freely than if it were left in the mold. v

Castings may thus be made to closer tolerances, and the present method makes sure the elimination of flaws because of the constant application of liquid metal under pressure to the molten side of the casting, as the casting solidies. There is no chance of getting drops of metal in the mold, as the metal wells up into the mold, due to the tilt of the mold with respect to its filling opening.`

Such drops frequently happen in the casting methods of the prior art on account of splashing or agitation, and such drops solidify on the way down into the mold, in the devices of the prior art. This cannot happen according to my method. Y

One of the most important features of the method is the freezing of the metal last at the mouth of the mold and at the beginning of the freezing at the point farthest away from the mouth of the mold. In some castings gates may be provided at the most remote point of the mold.r A rim around the casting may usually be avoided because such heavy pressures are no1; employed in my method as in die casting.

The castings, after removal from the mold, are preferably subjected to the uniform foundry temperature of approximately 65 degrees F.; and kept out of draft. They could also be quenched in water, if desired, but are preferably cooled uniformly by being subjected to a moderate and uniform cooling temperature so that they will contract in proportion, everywhere in the casting.

While I have illustrated a preferred embodiment of my invention, many modifications may be made without departing from the spirit of the invention, and I do not wish to be limited to the precise details of construction set forth, but desire to avail myself of all changes vWithin the scope of the appended claims.

Having thus described my invention, what I claim as new and desire to secureby Letters Patent of the United States is:

1. In an apparatus for casting, aladle for casting operations, comprising an external metal shell,v ,an internal metal shell, an insulating filling of mineral fibers between said shells, a lining of rebrick inside said second metal shell, and a ilr lining of smooth refractory inside said rebrick, said lining of smooth refractory dening a ladle chamber, said ladle chamber tapering and ex.- tending laterally toward a discharge opening at a lower part of said chamber for the supply-of metal 'to molds.

2. In an apparatus for casting, a ladle for casting operations, comprising an external metal shell, an internal metal shell, an insulating filling of mineral fibers between said shells, a lining` of firebrick inside said second metal shell, and a lining of smooth refractory inside said hrebrick, saidA lining of smooth refractory deiining a ladle chamber, said ladle chamber tapering and extendingl laterally toward a discharge opening ata lower part oi said chamber for the supply of metal to molds, said` ladle having surroimding said discharge opening a metal tting for the securement of a mold with its filling opening in registry with the discharge opening of said ladle.

3 In an apparatus for casting, a ladle for casting'y operations, comprising an external metal shell, an. internal metal shell, an insulating iilling of mineral fibers between said shells, a lining oi rebrick inside said second metal shell, and a lining ofv smooth refractory inside said firebrick, said lin-ing of smooth refractory defining a ladle chamber, said ladle chamber tapering and extending laterally toward a discharge opening at a lower part of' said chamber for the supply of metal to molds, said ladle having surrounding said discharge-,opening a metal fitting for the securement of a moldwith its lling opening in registry with the discharge opening of said ladle, said fitting, being provided with; guides for sliding complementary engagement with said molds whereby the molds may be moved laterally into and out of registry with the' opening ofthe ladle.

4.- InY an apparatus for casting'.- a ladle for casting. operations, comprising an external metal shell,an internal metalshell, an insulating filling ofmineralv iibers between said shells, a lining of rebrick inside said second metal shell, and a lining; of smooth refractory inside said lirebrick, said lining of' smooth refractorydeining a ladle chamber, said. ladle chamber tapering and extending; laterally toward a discharge opening at a lower partof said .chamber for the supply of metal to, molds said ladle being provided with a fixed refractory cover having a iilling aperture, and a movably mounted refractory cover for closing said aperture.

51, rIhe combination of a container for molten metal, with a pluralityv of furnaces arranged to discharge successively into said container, said container comprising a ladle having a metal shell, a layer of heat insulating material, an internal metal shell', rebricks, and a smooth refractory lining whereby the container is adapted to maintain the molten metal ata relatively high temperature, said container having a chamber provided with a cover and a downwardly and laterally extending tapered discharge opening, said cover having means for regulating the admission of air in controlling the discharge of molten metal,I guide means carried by said container adjacent said discharge opening, and a mold having an external metal shell, a refractory lining, and an internal molding shell, said internal shell being of a higher melting point than the metal used for casting, said-mold having a cavity disposed uppermost, and a lling opening extending downwardly and laterally into registry with the discharge opening of said container, and said mold having guide means for slidably engaging the guide means on said container whereby a plurality of said molds may be successively brought into registry and moved out of registry with the discharge opening of said container, and conveyor means for supporting said molds and facilitating their movement on said guide means whereby the container may be maintained lled with a predetermined high level of molten metal at a high temperature, and the metal may be caused to well up into the mold cavity so that the casting may cool from its remote end downward toward its filling opening andv any shrinkage may be taken up by the supply oi additional metal under pressure from said container, the molds being successively f applied to the discharge opening of said container to eiTect a continuous casting operation.

6. A casting apparatus comprising a ladle provided with a heat insulating lining for maintaining a supply of melted metal at a high temperature, said ladle being enclosed tov protect its contents against access to air, and said ladle having a streamlined discharge conduit adapted to be located below the free surface of the metal and under a relatively large head of meta-l at the time of discharge of metal from said ladle, and a mold having its filling opening of relatively large size and forming a continuation of said streamlined discharge conduit, said mold extending upward from its iilling opening at the time of filling of the mold, and being of relatively small size with respect to the capacity of said ladle, and means for controlling the flow of metal from said ladle to said mold to eiiect a smooth and continuous welling up of meltedmetal in a solid stream with its free surface progressing upward from the filling opening to the top of the mold, said ladle having a sufficient capacity to provide a gravity head of metal on the metal in said mold while the casting in the mold is cooling from the remote part of the mold toward the filling opening to supply additional metal under gravity head during the cooling, shrinkage, and congelation of the casting.

7. A casting apparatus comprising a ladle provided with a heat insulating lining for maintaining'a supply of melted metal at a high temperature, said ladle being enclosed to protect its contents against access to air, and said ladle having a streamlined discharge conduit adapted to belocated below the free surface oi the metal and under a relatively large head of metal at the time of discharge of metal from said ladle, and a mold having its iilling opening of relatively large size and forming a continuation of said streamlined discharge conduit, said mold extending upward from its filling opening at he time of filling of the mold, and being of relatively small size with respect to the capacity of said ladle, and means for controlling the flow of metal from said ladle to said mold to effect a smooth and continuous welling up of melted metal in a solid stream with its free surface progressing upward from the filling opening at the top of the mold, said ladle having a sufhcient capacity to provide a gravity head of metal on the metal in said mold while the casting in the mold is cooling from the remote part of the mold toward the filling opening to supply additional metal under gravity head during the cooling, shrinkage, and congelation of the castingsaid latter means comprising avalve in said streamlined discharge conduit, and means for periodically bringing additional molds into casting position. directly from said ladle.

8. The combination of an insulated container for melted metal with a plurality of furnaces arranged to discharge successively into said container, said container having a streamlined tapered discharge opening adapted to be located below the free surface of the metal and adjacent the bottom of the metal in the container, a guide means fora plurality of slidably mounted molds, said molds being carried by said guide means, and having relatively large lling openings adapted to be brought into registry with said streamlined conduit, a plurality of molds carried by said guide means, with their cavities extending upward from said lling opening, each mold following the other and being adapted to drive the previous mold from thev filling position when the succeeding mold comes into filling position, the melted metal in said container welling upward under gravity head into said molds successively in a solid uninterrupted stream until the molds are successively filled and maintained under gravity head while shrinkage and congelation takes place.

9. In an apparatus for casting with a high degree of uniformity of the product, the combination of a reservoir adapted to maintain the casting material at a predetermined temperature above the solidifying temperature, with a plurality of melting furnaces arranged in proximity to said reservoir, said melting furnaces being arranged to discharge successively batches of superheated casting material successively intok said reservoir for the purpose of raising the temperature and replenishing the heat to maintain the temperature of the casting material and to effect a mixture of successive batches with the remainder in said reservoirto increase the uniformity of the supply of casting material, said reservoir having a capacity in excess of the capacity of any furnace of the assembly, and a mold applied to and directly engaging said reservoir with the registry of a lling opening of said mold and a discharge opening of said reservoir at a point below the free surface of the metal at the time of casting so that the casting material may be forced into the mold by the gravity head of casting material in the reservoir.

10. In an apparatus for casting with a high degree of uniformity of the product, the combination of a reservoir adapted to maintain the casting material at a predetermined temperature above the solidifying temperature, with a plurality of melting furnaces arranged in proximity to said reservoir, said melting furnaces being arranged to discharge successively batches of superheated casting material successively into said reservoir for the purpose of raising the temperature and replenishing the heat to maintain the temperature of the casting material and to effect a mixture of successive batches with the remainder in said reservoir to increase the uniformity of the supply of casting material, said reservoir having a capacity in excess of the capacity of any furnace of the assembly, and a mold applied to said reservoir at a point below the free surface of the metal at the time of casting so that the casting material may be forced'into the mold by the gravity head of casting material in the reservoir, said mold having its major axis extending upwardly from the lling opening in said mold so that the casting material wells upward into the mold without separating from the main body of material in the reservoir.

11. In a ladle for casting having a unit construction adapted to be constructed in various sizes out of the same units, the combination of a plurality of metal housing members of substantial width adapted to form an outermetal shell,

said housing members being mounted with each successive'upper housing member supported on the upper edge of the lower one, and said housing members being of a predetermined width, with a plurality of upwardly extending outer frame members arranged in spaced relation about said housing members, with clamping bands extending between said outer frame members and engaging the metal housing members outside their joints to effect an alignment of the housing members and to clamp them in place by friction, and a lining of refractory material inside said shell,said lining being formed with a cavity for receiving a supply of molten metal.

l2. In a ladle for casting having a unit construction adapted to be constructed in various sizes out of the same units, the combination of a plurality of metal housing members of substantial width adapted to form an outer metal shell, said housing members being mounted with each successive upper housing member supported on the upper edge of the lower one, and said hous ing members being of a predetermined width, with a plurality of upwardly extending outer frame members arranged in spaced relation about said housing members, with clamping bands extending between said outer frame members and engaging the metal housing members outside their joints to effect an alignment of the housing members and to clamp them in place by friction,.and a lining of refractory material inside said shell, said lining being formed with a cavity for receiving a supply of molten metal, said lining being constructed of preformed blocks ofy unit height and predetermined thickness rwhereby the height of the ladle may be varied by using more or less of the housing members and blocks.

13. In a ladle for casting having a unit construction adapted to be constructed in various sizes out of the same Junits, the combination of a plurality of metal housing members of substantial width adapted to form an outer metal shell, said housing members being mounted with each successive upper housing member supported on the upper edge of the lower one, and said housing members being of a predetermined width, with a plurality of upwardly extending outer frame members arranged in spaced relation about said housing members, with clamping bands extending between said outer frame members and engaging the metal housing members outside their joints to eiect an alignment of the housing members and to clamp them in place by friction, and a lining of refractory material inside said shell, said lining being formed with a cavity for receiving a supply of molten metal, said lining being constructed lof preformed blocks of unit height and predetermined thickness whereby the height of the ladle may be varied by using more or less of the housing members and blocks, said ladle having an inner shell of metal housing members surrounding said` blocks, and a layer of heat-resistive and heat-insulating material between the inner and outer shell. Y

le. A cover construction for a ladle comprising a metal shell having a shape and plan substantially the same as the plan shape of the ladle, said shell having an outwardly extending attaching flange, and having an end plate, said end plate being formed with an aperture adapted to communicate with the ladle, said aperture being bordered by an inwardly extending frustoconical flange, an integral block of refractory material housed between said latter flange, said end plate, andl the outer wall of said cover shell, and ar second removable closure adapted to be inserted in said aperture to engage said frustoconical ange.

l5. A cover construction for a ladle comprising a metal shell having a shape and plan substantially the same as the plan shape of the ladle, said shell having an outwardly extending attaching ange, and having an end plate, said end plate being formed with an aperture adapted to communicate with the ladle, said aperture being bordered by an inwardly extending truste conical flange, an integral block of refractory material housed `netween said latter ange, said end' plate, and the outer wall of said cover shell, and a second removable closure adapted to be inserted in said aperture to engage said rustoconical flange, said removable closure comprising a metal shell having a top plate and a downwardly extending frusto-conical dange, and an integral block of refractory material shaped to and held by said latter frusta-conical flange.

i6. A cover construction for a ladle comprising a metal shell having a shape and plan substantially the same as the plan shape of the ladle, said-shell having an outwardly extending attaching liange, and having an end plate, said end plate being formed with an aperture adapted to cornniunicate with the ladle, said aperture being bordered by an inwardly extending irusto-conical flange, an integral blocl; of refractory material housed between said latter fiange, said end plate, and the cuter Wall of said cover shell, and a second removable closure adapted to be inserted in said aperture to engage said frusto-conical flange, said removable closure comprising a metal shell having a top plate and a downwardly eX- tending truste-conical flange, and an integral block of refractory material shaped to and held by said latter irusto-conical flange, said latter block having a through aperture, and manually controllable valve means for controlling the flow ofl air through said aperture.

i7. En an apparatus for casting, the combination of a ladle having a metal shell and a heat insulating lining formed with a reservoir chamber for molten metal, said chamber having a discharge opening for communicating with a mold, a mold directly connected to said ladle, and comprising a metal member having a cavity and having a iilling opening, said lling opening being connected to said discharge opening of said ladle, and said mold extending upward at the time of filling o1n said mold, said mold discharging the air in the empty cavity through leakage vents between the parts of said mold, and said ladle being provided with a substantially air-tight closure, valve means for controlling the admission of air to said ladle above the free surface of molten metal in said ladle, whereby the flow of molten metal upward into said mold is controlled by said valve means due to the differential in air pressure in said ladle and the air pressure on the metal of said mold.

CARL VESSEL. 

